Waterproofing membrane system and method

ABSTRACT

A waterproofing membrane system for waterproofing a concrete substrate is disclosed. The waterproofing membrane may comprise a first layer comprising a thermoplastic elastomeric waterproof material using advanced polymerization and squeeze technology. The second layer may comprise a carrier sheet that comprises a fabric. The third layer may comprise an adhesive to provide bonding of the first layer with a concrete substrate upon contact. In addition, the third layer may reduce migration of water and vapor traveling between the first layer and the concrete substrate. In some examples, the waterproofing membrane may also comprise a fourth layer to provide mechanical protection and ease of handling for the first layer, the second layer, and the third layer. In some examples, the first layer may comprise a thermoplastic polyolefin (TPO), the fabric may comprise polypropylene and/or polyethylene, the adhesive may comprise a C5 petroleum resin, and the fourth layer may be a protective coating comprising quartz sand (SiO2) having a reflectivity of 4.5%.

RELATED PATENT APPLICATIONS

This patent application is a continuation (CON) patent application of U.S. patent application Ser. No. 16/213,786, entitled “Waterproofing Membrane System and Method,” filed on Dec. 7, 2018, which claims priority to U.S. Provisional Patent Application 62/717,314, entitled “Waterproofing Membrane System and Method,” filed on Aug. 10, 2018.

TECHNICAL FIELD

This patent application relates generally to a waterproofing membrane system and method, and more specifically, to systems and methods for waterproofing a concrete substrate and other related waterproofing applications.

BACKGROUND

Laminate sheets are typically used for waterproofing concrete. These laminate sheets, however, are normally applied to a concrete substrate that has already been formed, such as a building foundation. As a result, such laminate sheets are applied on a cured concrete surface. In other concrete applications, laminate sheets can also be applied to concrete that is freshly-poured, or on surfaces that are not yet cured.

Conventional laminate sheets offer limited waterproofing capabilities when applied to either cured or non-cured concrete substrates. The integrity of a waterproofing membrane system is generally based on materials, size, dimensions, and arrangement of various layers. In many cases, conventional laminate sheets do not form an adequate water barrier or are cumbersome to use and install, which also results in poor waterproofing. In addition, conventional laminate sheets lack durability in extreme weather conditions and typically cannot accommodate heavy foot traffic or other physical wear.

As a result, a more robust waterproofing membrane system and method may be imperative to overcome the shortcomings of conventional systems and methods.

BRIEF DESCRIPTION OF DRAWINGS

Features of the present disclosure are illustrated by way of example and not limited in the following Figure(s), in which like numerals indicate like elements, in which:

FIG. 1 illustrates a cross-section of a waterproofing membrane system, according to an example;

FIG. 2 illustrates a cross-section of a waterproofing membrane system, according to another example; and

FIGS. 3A-3C illustrate cross-sections of various waterproofing membrane systems, according to an example.

DETAILED DESCRIPTION

For simplicity and illustrative purposes, the present disclosure is described by referring mainly to examples and embodiments thereof. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be readily apparent, however, that the present disclosure may be practiced without limitation to these specific details. In other instances, some methods and structures readily understood by one of ordinary skill in the art have not been described in detail so as not to unnecessarily obscure the present disclosure. As used herein, the terms “a” and “an” are intended to denote at least one of a particular element, the term “includes” means includes but not limited to, the term “including” means including but not limited to, and the term “based on” means based at least in part on.

As described above, conventional laminate sheets offer limited waterproofing capabilities when applied to either cured or non-cured concrete substrates. They lack durability and cannot accommodate heavy physical wear or extreme conditions. Use and installation of conventional laminate sheets are also cumbersome. In many cases, conventional laminate sheets do not provide an adequate water barrier for which they are created.

FIG. 1 illustrates a cross-section of a waterproofing membrane system 100, according to an example. As shown, the waterproofing membrane system 100 may include various layers. For example, the waterproofing membrane system 100 may have a first layer 102, a second layer 104, a third layer 106, and a fourth layer 108.

The first layer 102 may be a membrane layer. The membrane layer may be made of a thermoplastic elastomeric waterproof material using advanced polymerization together with squeeze technology having high tensile strength and resistant to oxidation and puncture. For example, the membrane may include a thermoplastic polyolefin (TPO). In another example, the membrane may include other various materials, such as elastomer (POE) plastic, EVA plastic, plasticizer, antioxidant, etc.

The second layer 104 may be a carrier sheet. In an example, the carrier sheet may include a fabric made of polypropylene. In some examples, the carrier sheet may be made of 100% polypropylene. Alternatively, the carrier sheet may be made of a fabric that includes a mix of polypropylene and polyethylene.

The third layer 106 may be an adhesive layer. In an example, the adhesive layer may be made of C5 petroleum resin. The adhesive layer may provide bonding of the membrane and concrete upon contact, as well as reduce migration of water and vapor traveling between these two materials.

The fourth layer 108 may be a protective coating. In an example, the protective coating may be made of quartz sand (SiO2) or other similar material(s). In some examples, the protective coating may have a reflectivity of 4.5%. Depending on application or purpose, the reflectivity may be greater than, equal to, or lesser than 4.5%. The protective coating may also provide mechanical protection for the membrane, carrier sheet, and/or adhesive layer as well, so that the surface of the membrane or other layers, for example, may be more easily handled. This may be especially important in transportation, storage, and application the waterproofing membrane on a concrete substrate.

FIG. 2 illustrates a cross-section of a waterproofing membrane system 200, according to another example. As shown, the waterproofing membrane system 200 may be similar to waterproofing membrane system 100 of FIG. 1 and include various layers. In the waterproofing membrane system 200 of FIG. 2, however, there may be only three total layers. The waterproofing membrane system 200 may have a first layer 203, a second layer 206, and a third layer 208. The second layer 206 may be an adhesive layer similar to that of the third layer 106 of FIG. 1, and the third layer 208 may be a protective coating similar to that of the fourth layer 108 of FIG. 1. The first layer 203 may be a carrier sheet that incorporates a membrane-like features. In effect, the first layer 203 may be an integrated version of the first layer 102 and the second layer 104 of FIG. 1.

Other various examples or variations may also be provided. For example, the layers of FIGS. 1 and 2 may be interchangeable, substituted, and/or arranged in an order different than what is shown.

FIGS. 3A-3C illustrate cross-sections of various waterproofing membrane systems, according to an example. FIG. 3A may depict a waterproofing membrane system that includes a single sheet 303. Sheet 303 may be the waterproof membrane system 100 of FIG. 1 or the waterproof membrane system 200 of FIG. 2. Here, sheet 303 may be a homogeneous waterproofing membrane system that does not include any other layer or component. Advantages of a homogeneous waterproofing membrane system is its relatively lightweight nature, making it easier to transport, store, and install.

FIG. 3B may depict a waterproofing membrane system that includes sheet 303 and a backing sheet 305. In an example, the backing sheet 305 may be a woven or a non-woven material. The backing sheet 305 may help with strength, durability of the waterproofing membrane system, or may help with use and installation of the waterproofing membrane system. It may also help protect the waterproofing membrane during transportation, storage, and application. Other various advantages may be apparent.

FIG. 3C may depict a waterproofing membrane system that includes two sheets 303 with a reinforcement sheet 307 therebetween. In an example, reinforcement sheet 307 may be a woven or a non-woven material. reinforcement sheet 307 may help with strength, durability of the waterproofing membrane system, or may help with use and installation of the waterproofing membrane system. It may also help protect the waterproofing membrane during transportation, storage, and application. Other various advantages may be apparent.

In an example, the waterproofing membrane system and method may follow the specifications outlined below in TABLE 1.

TABLE 1 INDEX ITEM H L (Fleece back) P The resin thickness of Middle fabric, mm≥ — Maximum tension, N/cm≥ — 200  250  Tension strength, Mpa≥ 12 — — Maximum tension elongation, %≥ — — 15 Fracture elongation, %≥ 500  250  — Heat treatment size change rate %≤  2  1   0.5 Low temperature bend −40° C. No crack Water tightness 0.3 Mpa, 2 h, No seepage Attack resistance 0.5 kg m, No seepage Static charge resistance — — 20 kg, No seepage Seam strip strength, N/mm≥ 4.0 or 3.0 Membranes break Right-angle tear strength, N/mm≥ 60 — — Trapezoid tear strength N≥ — 250  450  Bibulous rate After soaking≤ 4.0 (70° C. 168 h), % Air-cure later≥ −0.4  Heat aging Time  672 h (115° C.) Appearance No blister, flaw, delamination, coherence, hole Tensile strength — 90 90 retention, %≥ Elongation rate of 90 — — keeping, %≥ Low temperature bend −40° C., No crack Chemistry Appearance No blister, flaw, delamination, coherence, hole Tensile strength — 90 90 retention, %≥ Elongation rate of 90 — — keeping, %≥ Low-temperature bending −40° C., No crack Artificial Time 1500 h weather Appearance No blister, flaw, accelerated delamination, coherence, hole aging Tensile strength — 90 90 retention %≥ Elongation rate of 90 — — keeping %≥ Low temperature bend −40° C., No crack

In another example, the waterproofing membrane system and method may follow the specifications outlined below in TABLE 2 and TABLE 3.

TABLE 2 Dimensions (Nominal) TPO Waterproofing Membrane System Thickness 0.046 in. (1.2 mm) Roll size 6 ft. 6 in. × 65 ft. 7 in. (2 m × 20 m) Roll area 430 ft² (40 m²) Roll weight 132 lbs (60 kg) Minimum side/end laps 3 in. (75 mm)

TABLE 3 TPO Waterproofing Property Membrane System Color White Thickness 0.046 in. (1.2 mm) Lateral water migration resistance Pass at 180 ft (55 m) Low temperature flexibility −40° C. no leaking Resistance to hydrostatic head 180 ft (55 m) Elongation 612% Tensile strength, film 2262 psi (15.6 MPa) Crack cyclin at −9.4° F. (−23° C.), 100 Unaffected, Pass cycles Puncture resistance 184 lbs (820 N) Peel adhesion to concrete 4 lbs/in. (700 N/m) Lap peel adhesian at 72° F. (22° C.) 6.85 lbs/in. (120 N/m) Lap peel adhesian at 40° F. (4° C.) 5 lbs/in. (900 N/m) Permeance to water vapor 0/35 MPa × 2 h = 0.7 ng transmission

Furthermore, in some examples, weathering between −40° C. through 110° C. may not affect the waterproofing membrane system. The waterproofing membrane system may be environmentally friendly as well, and may not include chlorine and other hazardous materials. The waterproofing membrane system may also be extremely durable and have an effective life of up to 50 years. The waterproofing membrane system may include crack resistance. This waterproofing membrane system may be suitable for the construction of exposed or non-exposed roof waterproof layer. It may also be easy to shape along any surface area to provide waterproofing. In additional to concrete application, the waterproofing membrane system described herein may also be used on light steel roof, not only to reduce the weight of roofing, and excellent saving materials, waterproof and anti-condensation, suit for large industrial plants, public buildings. Other various waterproofing applications may be provided as well, such as for drinking water reservoirs, toilets, basements, tunnels, grain depots, subways, reservoirs, commercial, public, residential applications, etc.

What has been described and illustrated herein are examples of the disclosure along with some variations. The terms, descriptions, and figures used herein are set forth by way of illustration only and are not meant as limitations. Many variations are possible within the scope of the disclosure, which is intended to be defined by the following claims—and their equivalents—in which all terms are meant in their broadest reasonable sense unless otherwise indicated. 

1. A waterproofing membrane segment, comprising: a first layer segment comprising a thermoplastic elastomeric waterproof material using advanced polymerization and squeeze technology; a second layer segment comprising a first adhesive, wherein the second layer is disposed on the first layer; and a third layer segment comprising a protective coating to provide mechanical protection and ease of handling for the first layer and the second layer, wherein the third layer disposed on the second layer.
 2. The waterproofing membrane segment of claim 1, further comprising a fourth layer segment comprising a second adhesive, wherein the fourth layer is disposed under the first layer.
 3. The waterproofing membrane segment of claim 2, wherein the fourth layer segment comprises a length of approximately 10 cm.
 4. The waterproofing membrane segment of claim 1, wherein the protective coating comprises quartz sand (SiO2).
 5. The waterproofing membrane segment of claim 1, wherein the first layer segment comprises thermoplastic polyolefin (TPO).
 6. The waterproofing membrane segment of claim 1, wherein the first layer segment comprises at least one of an elastomer (POE) plastic, a EVA plastic, a plasticizer, and an antioxidant.
 7. The waterproofing membrane segment of claim 1, wherein the first adhesive comprises C5 petroleum resin.
 8. The waterproofing membrane segment of claim 1, wherein: the first layer segment comprises a length of approximately 2 m and a thickness of less than 1 mm; the second layer segment comprises a length of approximately 2 m and a thickness of less approximately 0.2 mm; and the third layer segment comprises a length shorter than the first layer and the second layer and a thickness of less approximately 0.1 mm.
 9. A waterproofing membrane system comprising at least one waterproofing membrane segment of claim 1, wherein the waterproofing membrane segment comprises an overall thickness of approximately 1.2 mm.
 10. A method of forming a waterproofing membrane system on a concrete substrate, the method comprising: providing a plurality of waterproofing membrane segments to form the waterproofing membrane system, each of the waterproofing membrane segments comprising: a first layer segment comprising a thermoplastic elastomeric waterproof material using advanced polymerization and squeeze technology; a second layer segment comprising a first adhesive, wherein the second layer is disposed on the first layer; a third layer segment comprising a protective coating to provide mechanical protection and ease of handling for the first layer and the second layer, wherein the third layer disposed on and exposing a portion of the second layer segment; and a fourth layer segment comprising a second adhesive, wherein the fourth layer is disposed under the first layer; and interconnecting the plurality of waterproofing membrane segments by attaching the exposed portion of the second layer segment of one waterproofing membrane segment with the fourth layer segment of another waterproofing membrane segment.
 11. The method of claim 10, wherein the first layer segment comprises thermoplastic polyolefin (TPO).
 12. The method of claim 10, wherein the first layer segment comprises at least one of an elastomer (POE) plastic, a EVA plastic, a plasticizer, and an antioxidant.
 13. The method of claim 10, wherein the first adhesive and the second adhesive comprise C5 petroleum resin.
 14. The method of claim 10, wherein the protective coating comprises quartz sand (SiO2).
 15. The method of claim 10, wherein: the first layer segment comprises a length of approximately 2 m and a thickness of less than 1 mm; the second layer segment comprises a length of approximately 2 m and a thickness of less approximately 0.2 mm; the third layer segment comprises a length shorter than the first layer segment and the second layer segment and a thickness of less approximately 0.1 mm; and the fourth layer segment comprises a length of approximately 10 cm.
 16. A waterproofing membrane segment, comprising: a first layer segment comprising a thermoplastic elastomeric waterproof material using advanced polymerization and squeeze technology; a second layer segment comprising a first adhesive, wherein the second layer is disposed on the first layer; a third layer segment comprising a protective coating to provide mechanical protection and ease of handling for the first layer and the second layer, wherein the third layer disposed on the second layer; and a fourth layer segment comprising a second adhesive, wherein the fourth layer is disposed under the first layer.
 17. The waterproofing membrane segment of claim 16, wherein: the first layer segment comprises a length of approximately 2 m and a thickness of less than 1 mm; the second layer segment comprises a length of approximately 2 m and a thickness of less approximately 0.2 mm; the third layer segment comprises a length shorter than the first layer segment and the second layer segment and a thickness of less approximately 0.1 mm, wherein the third layer segment disposed on and exposing an exposed portion of the second layer segment; and the fourth layer segment comprises a length of approximately 10 cm,
 18. The waterproofing membrane segment of claim 17, wherein the exposed portion of the second layer segment and the fourth layer segment provide interconnectivity with other waterproofing membrane segments.
 19. The waterproofing membrane segment of claim 16, wherein the waterproofing membrane segment comprises an overall thickness of approximately 1.2 mm. 